Synergistic effects of halloysite nanotubes with metal and phosphorus additives on the optimal design of eco-friendly sandwich panels with maximum flame resistance and minimum weight

Abstract The present work addresses the optimal design of sandwich panels made of flax fabric (FF)/vinyl ester (VE) composite face sheets and honeycomb VE core. The sandwich structures are first optimized in terms of flammability by obtaining the best combination of ammonium polyphosphate (APP), halloysite nanotube (HNT), and magnesium hydroxide (MH) as three flame retardants (FRs). Using the Taguchi method and horizontal burning test, it is shown that [6, 3, and 3%] and [1, 0.5, and 0%] are the optimal combinations of APP, HNT, and MH for the face sheets and core, respectively. Cone calorimeter test results indicate that the optimal FR combinations significantly decrease the mass lost rate (MLR), heat rate release (HRR), total smoke release (TSR), and maximum average release heat emission (MARHE). The FR sandwich structures are then geometrically optimized under compressive loads based on their weight. Different failure modes are considered as the design constraints of the optimization problem. Imperialist competitive algorithm (ICA), as a powerful meta-heuristic algorithm, is implemented to considerably reduce the computational cost of the optimization process. The results of this study show that proper combinations of FR additives can increase the flame retardancy while decreasing the weight of sandwich panels.